Electromagnetic cleaning process and device

ABSTRACT

The present invention discloses a process for cleaning oxides, slurry, dirt, impurities, organics and volatile matter, rust and other scales from substrates. This cleaning and surface preparation action is affected by abrasion, shaving or dry machining of the substrate material as caused by dry magnetic abrasive particles, either in powder or granule form, which engage the substrate material in a magnetic field. The passage of input current through a motor generates a magnetic field, which creates a “coupling” between two surfaces, the driving (stator) surface and the driven (rotor) surface. The magnetic coupling between the surfaces is provided by stiffening of the particles, which allows the mechanical abrasion that is necessary for the cleaning action on the substrate.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to U.S. ProvisionalApplication Serial No. 60/332,286, filed Nov. 21, 2001, the teachings ofwhich are incorporated herein by reference.

FIELD OF THE INVENTION

[0002] The present invention is directed to the field of electromagneticcleaning and more particularly to an apparatus and method for utilizingmagnetic abrasive particles in a generated magnetic field to cleansubstrates such as wire.

BACKGROUND OF THE INVENTION

[0003] The use of magnetic fields containing magnetic abrasive particlesfor engraving and machining workpieces is known in the art. (See, forexample, U.S. Pat. Nos. 6,036,580 to Igelshteyn et al.; 5,419,735 toImahashi et al.; 5,197,234 to Gillenwater; 4,821,466 to Kato et al.;4,306,386 to Sakulevich et al.; and 4,170,849 to Sakulevich et al., theteachings of all of which are incorporated herein by reference).However, it is has not been previously recognized that magnetic abrasiveparticles introduced between magnetically coupled surfaces can be usedto clean substrates.

SUMMARY OF THE INVENTION

[0004] The present invention discloses a process for cleaning oxides,slurry, dirt, impurities, organics and volatile matter, rust and otherscales from substrates. This cleaning and surface preparation action iseffected by abrasion, shaving or dry machining of the substrate materialas caused by dry magnetic abrasive particles, either in powder orgranule form, which engage the substrate material in a magnetic field. Amagnetic field generator generates the magnetic field, which creates a“coupling” between two surfaces, the driving (stator) surface and thedriven (rotor) surface. The magnetic coupling between the surfaces isprovided by stiffening of the particles, which allows the mechanicalabrasion that is necessary for the cleaning action on the substrate.

BRIEF DESCRIPTION OF THE DRAWING

[0005] The invention is described with reference to the several figuresof the drawing, in which:

[0006]FIG. 1 is a cross-sectional illustration of a substrate beingcleaned by magnetic abrasive particles in a generated magnetic fieldaccording to one embodiment of the invention;

[0007]FIGS. 2A and 2B are isometric illustrations of drive surfacesaccording to various embodiments of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0008] Referring now to the figures of the drawing, the figuresconstitute a part of this specification and illustrate exemplaryembodiments to the invention. It is to be understood that in someinstances various aspects of the invention may be shown exaggerated orenlarged to facilitate an understanding of the invention.

[0009] The present invention discloses a process for cleaning oxides,slurry, dirt, impurities, organics and volatile matter, rust and otherscales from substrates. This cleaning and surface preparation action isaffected by abrasion, shaving or dry machining of the substrate materialas caused by dry magnetic abrasive particles, either in powder orgranule form, which engage the substrate material in a magnetic field.In a preferred embodiment, the substrate material is an elongatematerial. In another preferred embodiment, the elongate material is incoiled form or in short lengths and is metallic in nature (with theductility and machinability characteristic of metallic materials). Inanother preferred embodiment, the metallic material is substantively ametal alloy based on aluminum, copper, or magnesium (or othernon-ferrous metals) or iron (e.g. steel). In another preferredembodiment, the elongate material is a wire of circular cross sectionthat is paid off a coil wound on a drum.

[0010] A magnetic field generator generates a magnetic field whichcreates a “coupling” between two surfaces, the drive (stator) surfaceand the driven (rotor) surface. In a preferred embodiment, the passageof input current through a motor with special laminations generates themagnetic field. FIG. 1 is a cross-sectional illustration of a drivensurface being cleaned by dry magnetic abrasive particles 30 in amagnetic field generated by a motor 40. The dry magnetic abrasiveparticles 30, either in powder or granule form, fill the gap 24 formedby the configuration of the drive surface 20 and is adapted to receivethe driven surface. In a preferred embodiment, the driven surface is thesubstrate 10 that is to be cleaned. In another embodiment, the gap 24between the surfaces could potentially comprise a fluid other than air.The magnetic coupling between the surfaces is provided by stiffening ofthe particles 30, which allows the mechanical abrasion that is necessaryfor the cleaning action on the substrate 10. The coupling creates anengagement between the substrate 10 and the dry magnetic abrasiveparticles 30 on the substrate. As shown in by the arrows in FIG. 1, thesubstrate 10 may be moved by a mechanism 14 that grips the substrate andmoves it in a translational, oscillatory or rotational motion in orderto effect and enhance the cleaning action of the magnetic abrasiveparticles.

[0011] In preferred embodiments, the input currents to the motor 40 aresquare or sinusoidal waveforms. In order to improve the response time,increase cleaning efficiency, and alleviate over-heating problems, themotor 40 can be operated in a “big bang” mode. This allows theapplication of larger input power for short bursts of time withoutdamaging the motor. To further prevent over-heating, oil or watercooling can be used independently with both the drive system and on thesubstrate material. Substrate cooling mechanisms 12 and drive coolingmechanisms 22 are illustrated in FIG. 1.

[0012]FIGS. 2A and 2B are schematic illustrations of drive surfacesaccording to various embodiments of the invention. FIG. 2A illustratesan embodiment in which the drive surface comprises two plates 50. FIG.2B illustrates an embodiment in which the drive surface comprises aslotted cylinder 52. Other configurations for the drive surface will beapparent to those of ordinary skill in the art.

[0013] The invention can be used independently or in conjunction with acombination of one or more other cleaning techniques employed inindustry today including chemical (low or high temperature),electrochemical, mechanical abrasion (e.g. mechanical rotors), andrinsing (ultrasonic, hot water, etc . . . ).

[0014] The present invention offers various advantages. The substrate tobe cleaned needs not be ferromagnetic as the cleaning action is effectedby the stiffening of the magnetic abrasive particles in the magneticfield. The invention is mobile and allows for the cleaning or polishingof substrates which must undergo pre-processing or post-processing, forexample in the application of a coating.

[0015] Other embodiments of the invention will be apparent to thoseskilled in the art from a consideration of the specification or practiceof the invention disclosed herein. It is intended that the specificationand examples be considered as exemplary only, with the true scope andspirit of the invention being indicated by the following claims.

What is claimed is:
 1. An apparatus for electromagnetic cleaning,comprising: at least one drive surface, wherein said at least one drivesurface is arranged so as to form a gap that is adapted to receive asubstrate; magnetic abrasive particles residing in said gap; and amagnetic field generator, wherein said generator generates a magneticfield so as to magnetically couple said drive surface with saidsubstrate when said substrate is introduced into said gap, and whereinsaid magnetic field causes said magnetic abrasive particles to engagesaid substrate.
 2. The apparatus of claim 1, further comprising at leastone cooling mechanism attached to said drive surface.
 3. The apparatusof claim 1, further comprising at least one cooling mechanism attachedto said substrate.
 4. The apparatus of claim 1, wherein said magneticfield generator is a motor adapted to receive an input current.
 5. Theapparatus of claim 4, wherein said input current is a sinusoidalwaveform.
 6. The apparatus of claim 4, wherein said input current is asquare waveform.
 7. The apparatus of claim 4, wherein said input currentis large and said motor is operated for multiple short periods of time.8. The apparatus of claim 1, wherein said at least one drive surfacecomprises two plates.
 9. The apparatus of claim 1, wherein said at leastone drive surface comprises a cylinder.
 10. The apparatus of claim 1,further comprising: means for moving said substrate.
 11. The apparatusof claim 1, wherein said magnetic abrasive particles are in powder form.12. The apparatus of claim 1, wherein said magnetic abrasive particlesare in granule form.
 13. A method for electromagnetic cleaning,comprising the steps of: generating a magnetic field so as tomagnetically couple two surfaces, wherein said surfaces comprise a drivesurface and a substrate and wherein said drive surface is arranged toform a gap adapted to receive said substrate; introducing magneticabrasive particles into said gap, wherein said magnetic field causessaid magnetic abrasive particles to engage said substrate.
 14. Themethod of claim 13, wherein said magnetic abrasive particles arestiffened by said magnetic field.
 15. The method of claim 13, furthercomprising moving said substrate so as to effect cleaning by saidmagnetic abrasive particles.
 16. The method of claim 13, wherein saidmagnetic field generator is a motor adapted to receive an input current.17. The apparatus of claim 16, wherein said input current is asinusoidal waveform.
 18. The apparatus of claim 16, wherein said inputcurrent is a square waveform.
 19. The apparatus of claim 16, whereinsaid input current is large and said motor is operated for multipleshort periods of time.
 20. A system for electromagnetic cleaning,comprising: a substrate at least one drive surface arranged so as toform a gap that is adapted to receive said substrate; magnetic abrasiveparticles residing in said gap; and a magnetic field generator, whereinsaid generator generates a magnetic field so as to magnetically couplesaid drive surface with said substrate when said substrate is introducedinto said gap, and wherein said magnetic field causes said magneticabrasive particles to engage said substrate.
 21. The system of claim 20,wherein said substrate is an elongate member of circular cross section.22. The system of claim 20, wherein said substrate is a non-ferrousmetal alloy.